Condensate drain assembly

ABSTRACT

The invention provides a condensate drain assembly comprising one or more reservoirs, a conduit, and a port defining an inlet to a drip channel. The reservoir is preferably constructed to have a floor that is shaped in a manner that allows the collected condensate to be directed to the conduit. For example, the floor may be partially concave and defined by a highest point at an inside wall of the reservoir that is about opposite to the entrance to the conduit and a lowest point at a bottom of the entrance to the conduit. Additionally, the floor at the entrance to the conduit may be further defined by a cone that is open at a top and a side entering the conduit to allow the condensate to be funneled to the conduit from the reservoir.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 61/416,051, filed on Nov. 22, 2010, which is incorporated by reference herein in its entirety.

FIELD OF INVENTION

The present invention relates to a condensate drain assembly, in particular, a condensate drain assembly designed for a roof mounted vehicle air conditioning unit.

BACKGROUND OF THE INVENTION

Recreational vehicles, as well as other types of vehicles, typically have roof-mounted air conditioners to supplement the cooling provided by air conditioning systems that cool the cab of the vehicle. However, typically these rooftop air conditioners are not equipped with a condensate collection system that diverts water along a preferred path away from the air conditioner and the vehicle. Rather, these air conditioning systems commonly allow condensate to drain from the air conditioner onto the vehicle and over the roof of the vehicle. Condensate that forms on the surface of the vehicle and that leaves the vehicle along the sides may cause unsightly stains to form along the side of the vehicle. Additionally, the condensate may lead to a more rapid deterioration of the external surface components of the vehicle such as through more rapid corrosion of metallic components.

While some rooftop air conditioners provide a pan to collect the condensate, they do not provide a drain for the condensate to be removed from the pan over a preferred drainage path.

Efforts to address the problems associated with condensate collection and removal fail to entirely remedy the problems associated with condensate that forms in the rooftop air conditioning systems. Some removal systems have been designed that rely upon vehicle movement and convective air passage to eliminate any condensate that forms from the air conditioning unit. However, this arrangement is not effective when the air conditioner is used and condensate forms while the vehicle is stationary.

Several prior art solutions focus upon providing drain pans that either have no drain or poorly designed drainage systems that are susceptible to plugging. One prior art solution has even suggested locating a drainage collection system inside the vehicle, which could present problems in the event leakage develops in the condensate removal system.

There continues to remain a need in the art for a condensate drain assembly for vehicle roof mounted air conditioning units that effectively removes water that forms from the unit away from the rooftop of the vehicle along a drainage path.

BRIEF SUMMARY OF THE INVENTION

Without intending to be bound by theory or functionality, the present invention addresses the deficiencies of prior vehicle rooftop air conditioner condensate collection and removal assemblies. For example, the profile of the condensate drain assembly of the invention is such that the assembly may be inserted among an air conditioning unit and the rooftop of a vehicle to collect condensate that forms in the air conditioning unit and direct that condensate in a preferred manner away from the point of collection.

In one aspect, the invention provides a condensate drain assembly. The condensate drain assembly has one or more reservoirs for collecting the condensate and a conduit coupled to each of the one or more reservoirs. The conduit defines a fluid channel through which the condensate flows. The condensate drain assembly also comprises a port in the conduit that defines the entrance to a drip channel.

Any or all of the one or more reservoirs include a conduit entrance that define the inlet to the conduit from the reservoir and a floor that is shaped to allow the condensate to be directed to the conduit entrance. For example, the floor of any or all of the one or more reservoirs is partially concave and defined by a highest point at an inside wall of the one or more reservoirs that is about opposite to the conduit entrance and a lowest point at a bottom of the conduit entrance.

The floor at the conduit entrance may be further defined by a cone that is open at a top and a side entering the conduit to ensure the condensate is funneled to the conduit.

In an embodiment of the invention, the condensate drain assembly has a small enough profile such that the assembly can be situated between an air conditioning unit and a rooftop of a vehicle. Furthermore, the drip channel may direct the condensate to a preferred disposal location such as away from the vehicle.

In an embodiment of the invention, the condensate drain assembly is configured to be integrated with a condensate drain pan and the drip channel directs the condensate to a preferred disposal location such as away from the vehicle.

Another aspect of the invention provides a method for directing condensate that is formed in an air conditioning unit to be disposed in a preferred location, the method having the steps of collecting a condensate, funneling the condensate to a conduit, and directing the condensate to a drip channel to dispose of the condensate in a preferred location.

At least one reservoir facilitates collecting the condensate, the reservoir defined by a floor that is shaped to facilitate the funneling of the condensate to a conduit. According to an embodiment of the invention, the floor is partially concave and defined by a highest point at an inside wall of the reservoir that is about opposite to an entrance to the conduit and a lowest point at a bottom of the entrance to the conduit. The floor at the entrance to the conduit may also be further defined by a cone that is open at a top and a side entering the conduit to further promote the funneling of the condensate to the conduit.

Other aspects and embodiments will become apparent upon review of the following description taken in conjunction with the accompanying drawings. The invention, though, is pointed out with particularity by the appended claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

Having thus described the invention in general terms, reference will now be made to the accompanying drawing, which is not necessarily drawn to scale, and wherein:

FIG. 1 is a top view of a condensate drain assembly in accordance with an embodiment of the present invention;

FIG. 2 is a front view of a condensate drain assembly in accordance with an embodiment of the present invention; and

FIG. 3 is a side view of a reservoir in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter, in which some, but not all embodiments of the inventions are shown. Preferred embodiments of the invention may be described, but this invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The embodiments of the invention are not to be interpreted in any way as limiting the invention.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the descriptions herein. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.

As used in the specification and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly indicates otherwise. For example, reference to “a reservoir” includes a plurality of such reservoirs and reference to “an entrance” includes a plurality of such entrances.

The present invention provides a condensate drain assembly for collecting and removing water that forms from vehicle rooftop air conditioning systems.

The present invention provides improvements over condensate drainage systems known in the art by providing more reliable condensate removal along a directed path that will not discolor or accelerate corrosion of the surfaces of the vehicle.

The condensate drain assembly of the invention may be used in any vehicle that has a rooftop mounted air conditioning system, such as, for example, recreational vehicles. The condensate drain assembly may also be used in other air conditioning systems that suffer similar problems associated with condensate collection and removal.

The inventor has discovered that the design of the inventive condensate drain assembly has a small enough profile such that the assembly can be situated between the air conditioning unit and the rooftop of the vehicle. Furthermore, the inventor has discovered that the shape of the internal portion of the one or more reservoirs of the condensate drain assembly is constructed such that condensate droplets from the air conditioning unit that are collected by the one or more reservoirs are favorably, from a fluid hydraulic standpoint, directed to a conduit. The conduit then funnels the collected condensate through a port that defines the inlet to a drip channel that directs the collected condensate away from the air conditioning unit.

FIG. 1 is a top view of a condensate drain assembly according to an embodiment of the present invention. According to this embodiment, the condensate drain assembly 1 comprises a left reservoir 10 and a right reservoir 12, the left reservoir 10 and the right reservoir 12 positioned such that they can collect water that forms from the air conditioning unit.

The left reservoir 10 and the right reservoir 12 are affixed to a support 14. In this exemplary embodiment the support 14 is a base member that substantially surrounds, indeed exceeds, the entire area occupied by the left reservoir 10 and the right reservoir 12. In other embodiments of the invention, the support 14 may have other configurations. For example, the support 14 may be a base member that does not substantially surround the entire are occupied by the left reservoir 10 and the right reservoir, but may instead be a base support member that is affixed to only a portion of each of the bottoms of the left reservoir 10 and the right reservoir 12. In still other embodiments of the invention, the support 14 may affix to either the back side or the front side of the left reservoir 10 and the right reservoir 12 relative to the positions as shown in FIG. 2. Of course, if the support 14 is configured to affix to the front portion of the left reservoir 10 and the right reservoir 12, then a cutout or an orifice would be needed through which the drip channel 20 could pass.

Other supports, according to certain embodiments of the invention, allowing the left reservoir 10 and the right reservoir 12 to form a unitary body through which water can be collected and discharged can be envisioned. For example, the conduit 16, as further described below, may serve to attach the left reservoir 10 and a right reservoir and hold them together in a rigid manner.

In yet other embodiments of the invention, a support can be provided that allows the left reservoir 10 and the right reservoir 12 to be more flexibly positioned at the air conditioning unit to allow for the most optimum collection of condensate. Pursuant to this embodiment, the conduit 16 may be constructed of a flexible material allowing the left reservoir 10 and the right reservoir 12 to be rotationally positioned about a center axis defining the conduit 16. Further pursuant to this embodiment, a support may also be constructed of a flexible material, particular in those embodiments when the support is configured to be affixed to the back side or the front side of the left reservoir 10 and the right reservoir 12.

As condensate collects in the left reservoir 10 and the right reservoir 12, the collected condensate flows into a conduit 16 that is coupled to or interconnected with the left reservoir 10 and the right reservoir 12. The conduit 16 defines a fluid channel network through which the collected condensate may flow. Water that enters the conduit 16 will then flow through the port 18 that defines the inlet of the drip channel 20. The drip channel 20 may be of any desired length that allows the collected condensate to be directed away from the air conditioning unit. The drip channel 20 may be, for example, a tubing, a gutter, and any combination thereof. The drip channel 20 may assume any configuration that allows water to be carried away from the condensate drain assembly 1 where the condensate is collected.

In certain embodiments of the invention, the bottom of the support 10, for example, in this illustrative embodiment, or the bottom surfaces of the left reservoir 10 and the right reservoir 12 in embodiments when the support is not a base support as illustrated in FIGS. 1 and 2 are constructed such that the condensate drain assembly 1 may be attached and securedly affixed to a surface. In an embodiment of the invention, the surface of the condensate drain assembly 1 that is to be affixed to another surface to hold the assembly in place is provided with an adhesive backing. In preferred embodiments of the invention, the adhesive backing would have a pull-away sheet that would then expose the adhesive material

In certain embodiments of the invention, particularly in those embodiments when the surface to which the condensate drain assembly 1 is to be attached is a metal, a magnetic material may be selected for the support 14 or the left reservoir 10 and the right reservoir 12, depending on which member is to be affixed to the surface.

In other embodiments of the invention, a sleeve that is configured to fit over the condensate drain assembly 1 while still allowing the left reservoir 10 and the right reservoir 12 to remain open for the collection of condensate may be adhesively or magnetically affixed to the surface to which the condensate drain assembly 1 is to be attached.

In still other embodiments of the invention, the condensate drain assembly 1 may be more permanently affixed to another surface. For example, according to this embodiment, the condensate drain assembly 1 may be welded, riveted, screwed, etc. to the another surface.

As a person of ordinary skill in the art having the benefit of this disclosure will understand, a condensate drain assembly may be constructed of any number of reservoirs. In certain embodiments of the invention, such as those shown in the illustrative embodiments of FIGS. 1 and 2, the condensate drain assembly will have two reservoirs. In certain other embodiments of the invention, the condensate drain assembly will be constructed to have three, four, five, six, seven, eight, nine or more reservoirs. Of course, according to embodiments of the invention having more than two reservoirs, the conduit is constructed such that it interconnects with each of the reservoirs and typically funnels the water to a single port defining the inlet of the drip channel. In certain other embodiments of the invention, there may be more than one port configured into the conduit each defining a drip channel through which water is directed.

In yet another embodiment of the invention, the condensate drain assembly is constructed of a single reservoir that collects condensate. Similarly, the collected condensate leaves the reservoir through a conduit, port and drip channel.

In certain embodiments of the invention, the size of the condensate drain assembly will be such that it can be situated between the air conditioning unit and the rooftop of the vehicle. Indeed, without intending to be bound by theory, both the profile and shape of the inside of the one or more reservoirs of the condensate drain assembly are some of the inventive features associated with the case. In an embodiment of the invention, the condensate drain assembly will have a profile and a size such that it can be situated between the air conditioning unit and the rooftop of the vehicle to collect condensate that forms in the air conditioning unit.

In certain embodiments of the invention, the condensate drain assembly is configured to be integrated with a condensate drain pan and directs the water collected in the pan to a preferred disposal location.

In an embodiment of the invention, the length of the condensate drain assembly as measured from reservoir to reservoir as shown, for example, in FIG. 2 (embodiment of the invention having two reservoirs), is from about 1 inch (2.5 cm) to about 18 inches (46 cm), from about 2 inches (5 cm) to about 12 inches (30 cm), from about 2 inches (5 cm) to about 6 inches (15 cm), and from about 2.5 inches (6 cm) to about 4 inches (10 cm). In a certain embodiment of the invention, the length of the condensate drain assembly is about 3 inches (8 cm).

In an embodiment of the invention, the width or depth of the condensate drain assembly as measured across a reservoir, for example, is from about 1 inch (2.5 cm) to about 12 inches (30 cm), from about 1.5 inches (4 cm) to about 9 inches (23 cm), from about 1.5 inches (4 cm) to about 6 inches (15 cm), and from about 2 inches (5 cm) to about 3.5 inches (9 cm). In a certain embodiment of the invention, the width of the condensate drain assembly is about 1.5 inches (4 cm).

In an embodiment of the invention, the height of the condensate drain assembly from the bottom to top of a reservoir, for example, is from about 0.1 inch (0.25 cm) to about 3 inches (8 cm), from about 0.25 inch (0.6 cm) to about 2.5 inches (6 cm), from about 0.5 inch (1.3 cm) to about 2 inches (5 cm), and from about 0.75 inch (2 cm) to about 1.5 inches (4 cm). In a certain embodiment of the invention, the height of the condensate drain assembly is about 1 inch (2.5 cm).

The inside portion of the reservoir can be of any shape. However, according to certain embodiments of the invention, the shape of the inside portion of the reservoir is such that it facilitates the any collected condensate or condensate droplets to flow to the conduit to allow the condensate to be directed to the drip channel.

In an embodiment of the invention, the inside portion of the reservoir is the shape of a cylinder. In another embodiment of the invention, the inside portion of the reservoir is in the shape of a cylinder but the bottom of the reservoir do not meet at defined edges but rather are smoothed to facilitate the movement of condensate collected in the reservoir to the conduit to allow the collected condensate to be directed through the drip channel.

In an exemplary embodiment of a reservoir 22 illustrated in FIG. 3, the reservoir is comprised of an inside portion 24, a floor 26, and a conduit entrance 28. In this exemplary embodiment, the floor 26 of the reservoir 22 is semispherical recessed, for example, partially downwardly concave in a partial bowl shape, such that condensate droplets that are collected at position in the reservoir that is not proximate to the conduit entrance 28 will be directed to the conduit entrance 28 allowing the condensate to then enter the drip channel.

In an embodiment of the invention, the portion of the floor 26 of the reservoir 22 that is proximate to the conduit entrance 28 where the condensate is removed from the reservoir is sloping toward the conduit entrance 28 to allow the collected condensate to be removed from the reservoir. In this exemplary embodiment, the floor that is partially concave is defined by a highest point at an inside wall 32 of the one or more reservoirs that is about opposite to the conduit entrance 28 and a lowest point at a bottom of the conduit entrance 28 at the top of cone 30 (as further discussed herein). About opposite, as used herein, means any point of the inside wall of the reservoir 22 that is approximately diametrically opposed to the conduit entrance 28 as well as any point along the inside wall within about forty-five (45) degrees of a radial direction of the point that is diametrically opposed to the conduit entrance 28. In certain other embodiments of the invention, about opposite means any point along the inside wall within about forty (40), about thirty (30), about twenty-five (25), about twenty (20), about fifteen (15), about ten (10), and about five (5) degrees of a radial direction of the point that is diametrically opposed to the conduit entrance 28.

In certain embodiments of the invention, the floor 26 of the inside portion 24 of the reservoir 22 that is substantially located near the conduit entrance 28 is configured to be a cone 30 that is open at the top and the side entering the conduit to ensure the condensate or condensate droplets collected by the reservoir are funneled to the conduit.

An embodiment of the invention is directed to a method that includes the steps of collecting a condensate, funneling the condensate to a conduit, and directing the condensate to a drip channel to dispose of the condensate in a preferred location. For example, a condensate drain assembly of the invention may be used to facilitate carrying out the steps of the method of the invention.

Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the descriptions herein and the associated drawings. It will be appreciated by those skilled in the art that changes could be made to the embodiments described herein without departing from the broad inventive concept thereof. Therefore, it is understood that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims. 

1. A condensate drain assembly comprising: one or more reservoirs configured to collect a condensate; a conduit coupled to each of the one or more reservoirs, the conduit defining a fluid channel through which the condensate flows; and a port in the conduit that defines an entrance to a drip channel, wherein the one or more reservoirs each include a conduit entrance defining an inlet to the conduit and a floor that is shaped to allow the condensate to be directed to the conduit entrance.
 2. The condensate drain assembly according to claim 1, wherein the floor is partially concave and defined by a highest point at an inside wall of the one or more reservoirs that is about opposite to the conduit entrance and a lowest point at the conduit entrance.
 3. The condensate drain assembly according to claim 2, the floor at the conduit entrance is further defined by a cone that is open at a top and a side entering the conduit to ensure the condensate is funneled to the conduit.
 4. The condensate drain assembly according to claim 1, wherein the condensate drain assembly has a small enough profile such that the assembly can be situated between an air conditioning unit and a rooftop of a vehicle and the drip channel directs the condensate to a preferred disposal location.
 5. The condensate drain assembly according to claim 1, wherein the condensate drain assembly is configured to be integrated with a condensate drain pan and the drip channel directs the condensate to a preferred disposal location.
 6. A method comprising: collecting a condensate; funneling the condensate to a conduit; and directing the condensate to a drip channel to dispose of the condensate in a preferred location.
 7. The method according to claim 6, wherein a reservoir collects the condensate and is defined by a floor that is shaped to facilitate the funneling of the condensate to a conduit.
 8. The method according to claim 7, wherein the floor is partially concave and defined by a highest point at an inside wall of the reservoir that is about opposite to an entrance to the conduit and a lowest point at a bottom of the entrance to the conduit.
 9. The method according to claim 8, wherein the floor at the entrance to the conduit is further defined by a cone that is open at a top and a side entering the conduit to further promote the funneling of the condensate to the conduit. 